Prefabricated building

ABSTRACT

A building construction made up of a plurality of interlocking modular sections each section forming part of the floor and wall and/or roof and wall portions.

3,201,907 8/1965 Henderson ..52/79 ftates Patent 1191 1111 3,729,875

1451 May 1,1973

15 1 PREFABRICATED BUILDING 3,501,875 3/1970 Dc Mailly 52/70 2,103,894 12/1937 Bussmann 1 52/583 [76] Inventor Raymmd 56 Rugby Place 2,345,500 3/1944 Fetter I ..52/73 Montreal West, Quebec, Canada [22] Filed: Dec. 17, 1970 [2] Appl. No.: 99,023

3,520,098 7/1970 Johnston ..52/79 FOREIGN PATENTS OR APPLICATIONS 1,329,921 5/1973 France ..52/236 127,493 4/1948 Australia. ....52/79 51 1m.c1. ..E04b 1/348 "1" 1 Fieldofsearch lllllllllllllllll 52/79236, 73,218, 280,092 4/1952 SWllZLl'ldnd ..52/218 Primary Examiner-Frank L. Abbott 5 6] Reerences Cited Axszslam ExammerHenry E. Raaluazo Attorney-Alan Swabey, UNITED STATES PATENTS [57] ABSTRACT 3,287,865 11 1966 Lo km n ,52 79 A building construction made up of a plurality of in- 3,488,901) 1/1970 Ried ..52/79 terlocking modular sections each section forming part 3,564,787 2/1971 Sherman /7 of the floor and wall and/or roof and wall portions. 3,629,983 l2/l97l Jenn ..52/79 3,455,075 7/1969 Frey ..52/79 7 Claims, 14 Drawing Figures Patented May 1, 1973 4 Sheets-Sheet 1 INVENTOR Raymond FELSON Patented May 1, 1973 4 Sw ms-Sheet 5 INVENTOR Raymond FEL SON I A TTORNEY Patented May 1 1 973 4 Sheets-Sheet 4 ,3 INVENTOR Raymond FELSON ATTOMEY f PREFABRICATED BUILDING BACKGROUND OF INVENTION 1. Field of Invention The present invention refers to a novel building construction and particularly to a building made up of a number of modular preformed sections which are interlocked finesse.

2. Description of Prior Art.

Heretofore, particularly in the conventional manner of building houses and the like, a wooderi frame or the like is first set up and then walls and finishing are mounted to the primary frame, the cost involved in making such houses has risen to astronomical figures particularly in view of the high cost of specialized labor. In the recent past, many developments have been made relating to prefabricated houses, was to reduce the cost of onsite labor. However, the cost has been shifted from the site into the factory where the preformed walls and floors are still made according to conventional methods. In large apartment houses, new precast concrete complete units have been produced which can be stacked one on top of the other or suspended from a main center frame. However, these larger precast units are expensive to make and the transportation costs are at times formidable.

SUMMARY OF INVENTION It is an aim of the present invention to produce a relatively inexpensive building which is made up of precast sections interlocked together on site. It is an aim of the present invention to produce these modular sections so that they are inexpensive to mould and transport and yet since'only a few sections make up a house unit, they are quite easily assembled on site with minimum of labor.

A constructionin accordancewith the present invention includes a building structure made up of a plurality of interlocking members each comprising a first loadbearing panel and a second load-bearing panel integral with the first load-bearing panel along at least one edge thereof with the second load-bearing panel extending normal to the first panel. Of course, one of the panels can'represent the floor or ceiling while the other panel normal to the first panel represents the wall portion adjacent the floor or ceiling. These modular sections can be easily related to one another so that they interlock and certain sections form the floors and walls while the other sections form the ceilings and part of the walls. It is also contemplated that certain of the sections would include two wall portions extending along two edges of a floor portion.

Furthermore, novel fastening means can be provided at the edges of the units for fastening the units in an interlocking arrangement to form the house.

- IN THE DRAWINGS Having thus generally described the invention, the same will now be described in more detail and reference will be made to the accompanying drawings illustrating embodiments thereof and in which:

FIG. I is a perspective view of one embodiment ofa house constructed in accordance with the present invention;

FIG. 2 is an exploded perspective view of a house construction shown in FIG. I;

FIG. 3 is a front elevation of another embodiment showing the multi-level building in accordance with another embodiment of the present invention;

FIG. 4 is a partial vertical cross section taken through the multi-storey building of FIG. 3;

FIG. 5 is a typical floor plan taken as a horizontal I cross section along lines 5-5 of F IG 3;

FIG. 6 is a perspective view of the framing which can be used in one embodiment of a modular section used in the construction described;

FIG. 7 is a fragmentary perspective view of a detail of a modular section showing in dotted lines various utility the abutting wall ends showing the connectors of FIGS.

9 and I0 in a mating condition;

FIG. 12 is a perspective view of an anchor element which can be used on the top ends of the abutting walls for retaining the walls together;

FIG. 13 is a vertical cross section taken through line 13-13 ofFIG. 12; and

FIG. 14 is a vertical cross section taken through line l4l4 of FIG. 12.

Referring now to the drawings, particularly ,to FIGS. 1 and 2, an embodiment of the invention as shown is a one-storey single dwelling house 1.0 shown sitting on a foundation pad 12. However, in most cases, a foundation pad may not even be required. As shown in FIG. 2, the house is made up of ratherlarge components which can be. assembled on site. Each one of the sections 26,

28, 30 and 32 for instance can be moulded or cast in one piece and shipped to the site for assembling. Module section 28 for instance includes floor portion 24a, part of a wall 14a at right angles to the floor por tion and integral therewith along the outer edge of the floor. In this case, two upstanding walls are provided beyond two edges of the floor as: shown. Each outer module section 30, 32 and 26 include similar elements and their subscripts are raised by a successive letter of the alphabet. Each module 26, 28, 30 and 32 of this embodiment is of .a rectangular shape so that when they are connected together their joints are staggered and are interlocked.

The roof is similarly constructed with module sections 34, 36, 38 and 40. The roof module section 34 for instance has a roof panel 33a and side flanges 35a extending at right angles to the roof panel 33a and these flanges 35a sometimes form part of the wall structures. It is preferable in assembling the various roof module sections 34, 36, 38 and 40 which are of similar rectangular outline to the floor and wall modules to stagger them in a situation which is different from the floor and wall modules so that they overlap to reinforce the interlocking of the various parts making up the house.

In a square outline building, such as the one shown in FIG. I a square aperture is left after the roof modules 34, 36, 38 and 40 are assembled. This is suitable for mounting the utility unit 20 which can carry air-conditioning equipment and heating equipment. This utility housing 20 can be assembled in one piece as the other modules and easily dropped into a place fit on site.

All of the floor and wall portions 24 and 14 respectively of the various modules are of course load-bearing to support the roof members. The modules 26, 28, 30 and 32 as well as roof modules 34, 36, 38 and 40 could for example be made of precast concrete which is properly reinforced. Each one of the modules could easily be carried to the building site. Since all of the module parts are open they are easily moulded and are normally constructed in an elongated rectangular outline and are easily transported on average highways.

Referring now to FIGS. 3, 4 and 5, an embodiment is shown wherein a plurality of single dwellings or the like can be stacked in a multi-level type of building 42. In this construction, a foundation block such as indicated at 44 would be first located below the ground surface and then an access housing 46 which would be constructed as a single load-bearing unit would be placed on the foundation 44. In access housing 46, a portion of an elevator shaft or a staircase could be provided. Shoulder 43 would be provided on the upper edge of the access housing 46 and at least four rectangular load-supporting floor and wall module sections represented by 47 and 51 could be mounted interlocking with and resting on the shoulder 43 provided on the upper edge of the access dwelling 46. Each of the modules 47,51 include floor portions 48a and wall portions 580 with the other modules having successively raised alphabetical letter subscripts. The floor portion 484 would of course be tapered and heavily reinforced towards the center thereof so as to support the weight of the first unit as well as additional units. Loadsupporting roof portions 52a to 52d could be provided as seated on the wall portions 50a through 50d and staggered in the manner shown in FIGS. 1 and 2. The roof portions 52a to 52d could be heavily reinforced so as to support the load of additional units above it. However, it has been contemplated to extend the intermediate housings 46 and 54 so that the load is supported by the so-formed central core. Intermediate access housing 54 can be provided in the'opening left by the overlapping interlocking roof portions 52a to 52d and could be a continuation of an elevator shaft or an additional stairway to give access to a stacked unit on top of the housing 54.

The stacked unit would include staggered interlocking module sections 55 through 57 with each module 55 including floor portions 56a and wall portions 5811. Such portions would also be load supporting to support the roof thereon. The roof portions 600 to 60d would of course overlap in the same fashion as shown in FIGS. '1 and 2 while a utility housing 62 can be provided on the uppermost unit.

FIG. illustrates a typical floor plan of for instance the second unit shown in FIG. 3 and illustrates how the joints between the modules would correspond with the dividing walls.

By making use of the intermediate access housing as shown in FIGS. 3 and 4 each roof portion of one dwelling can act as a terrace for an upper dwelling.

Reference will now be made to FIGS. 6 through 8. It has also been contemplated to reduce the module seetions either for the floor and walls or for the roofs by moulding these modules of very light plastic materials such as polyurethane. In such cases, it would be preferable to make a basic frame, of aluminum or other relatively light but strong material, such as shown in FIG. 6 which includes beams 68 forming the floor 69 and uprights 66 forming the wall portion 67. The structure would be provided with window openings 70 in the wall portions 67.

FIG. 8 shows a partial cross section of a dwelling in which the floor and wall is made up of polyurethane with the frame of FIG. 6 incorporated therein.

FIG. 7 illustrates an embodiment wherein plumbing and electrical access would be premoulded in the walls of the modules.

The module sections can be connected together in any conventional fashion. However, FIGS. 9 through 11 show a preferred form of connecting abutting walls together. FIG. 9 shows the female connecting member including a base plate 80, an inverted channel 82 and slots 84. FIG. 10 shows the male connecting member 78 which includes a channel 86 with anchoring flanges 88 caught in the moulded material. Projecting plates 90 are provided on the face of the channel 86 and adapted to pass through the slots 84. When the ends of two walls are abutting and the projecting plates are within the slots 84, the pin 94 can be dropped through the aligning apertures 92 thereby locking the two connecting members. In addition to the above-mentioned connecting members a top end anchoring device such as shown in FIGS. 12 through 14 can be provided which includes a channel 98 and anchor pins 100. Corresponding aperwalls and one pin 100 would be in an aperture in each of the abutting end walls with the channel 98 fitting over the sides of the walls.

Of course, many other embodiments or structures could be made incorporating the present invention as defined in the claims. For instance, the above embodiments can be constructed relatively inexpensively and can be mounted quickly for relatively unaccessible areas. For instance, the embodiment shown in FIGS. 6 and 8 wherein the walls and floor can be made of polyurethane and other light plastic material moulded about a frame shown in FIG. 6. Such modules can be carried into remote forested areas by helicopter and assembled on site by relatively few laborers using but the simplest of tools to move the modules together and connect them. 1

lclaim:

1. A building structure consisting of eight modular units for assembly on site, each modular unit comprising a rectangular base panel bordered on two intersecting outer edges by projecting wall panels meeting to form a corner of the building, the other two edges of the base panel comprising inner edges, means at the edges of the base panel and wall panels for assembling the components in building units comprised of four of the components, each four components forming a floor-and-wall assembly and a separate roof-and-wall assembly, the four components of one of the assemblies being assembled at the base panel, normal to an adjacent component with the shortest inner edge of one base panel parallel to the longest inner edge of an adjacent base panel and in which the projecting wall panels are substantially coplanar and form a rectangular closed wall for the respective assemblies, one assembly being juxtaposed on the other assembly at the edges of its projecting walls forming a complete enclo sure, the joining vertical edges of the side panels of the assembly being horizontally spaced from the corresponding vertical joining edges of the side panel upon which it isjuxtaposed so that vertical load bearing sides of the assemblies have no vertical joints in direct overlying relation, the base panels of the respective assemblies being connected to form a floor, or root panel and including means for receiving means for closing an opening formed by portions of the inner edges of the base panels.

2. A building structure as defined in claim I wherein each component is pre-cast of mouldable material and is reinforced to support loads.

3. A building structure as defined in claim 2 wherein the components include means defining precast window and door openings in certain of the wall panels.

4. A building structure as claimed in claim 3 wherein releasable connecting means are provided between abutting edges of the wall panels and base panels.

5 A building structure as defined in claim 1, wherein a plurality of building structures are stacked one above the other with intermediate members mating with a center aperture formed by the mating of said rectangular base panels, said intermediate members defining the access housing between the building structures, and said components when assembled in an interlocking structure being self-supporting and load-supporting.

6. A building structure as claimed in claims 1 wherein the components areprovided with a primary frame on which is moulded a light plastic material.

7. A building structure as claimed in claim 1 wherein releasable connecting means are provided between the abutting edges of the wall panels, said releasable connecting means includes a channel having a plurality of spaced-apart projections on said channel, another channel member mounted on the edge of another abutting wall panel and having a plurality of slots receiving the projections on said other connecting member, said projections each including an aligned aperture through which a drop pin is removably disposed. 

1. A building structure consisting of eight modular units for assembly on site, each modular unit comprising a rectangular base panel bordered on two intersecting outer edges by projecting wall panels meeting to form a corner of the building, the other two edges of the base panel comprising inner edges, means at the edges of the base panel and wall panels for assembling the components in building units comprised of four of the components, each four components forming a floor-and-wall assembly and a separate roof-and-wall assembly, the four components of one of the assemblies being assembled at the base panel, normal to an adjacent component with the shortest inner edge of one base panel parallel to the longest inner edge of an adjacent base panel and in which the projecting wall panels are substantially coplanar and form a rectangular closed wall for the respective assemblies, one assembly being juxtaposed on the other assembly at the edges of its projecting walls forming a complete enclosure, the joining vertical edges of the side panels of the assembly being horizontally spaced from the corresponding vertical joining edges of the side panel upon which it is juxtaposed so that vertical load bearing sides of the assemblies have no vertical joints in direct overlying relation, the base panels of the respective assemblies being connected to form a floor, or roof panel and including means for receiving means for closing an opening formed by portions of the inner edges of the base panels.
 2. A building structure as defined in claim 1 wherein each component is pre-cast of mouldable material and is reinforced to support loads.
 3. A building structure as defined in claim 2 wherein the components include means defining precast window and door openings in certain of the wall panels.
 4. A building structure as claimed in claim 3 wherein releasable connecting means are provided between abutting edges of the wall panels and base panels.
 5. A building structure as defined in claim 1, wherein a plurality of building structures are stacked one above the other with intermediate members mating with a center aperture formed by the mating of said rectangular base panels, said intermediate members defining the access housing between the building structures, and said components when assembled in an interlocking structure being self-supporting and load-supporting.
 6. A building structure as claimed in claims 1 wherein the components are provided with a primary frame on which is moulded a light plastic material.
 7. A building structure as claimed in claim 1 wherein releasable connecting means Are provided between the abutting edges of the wall panels, said releasable connecting means includes a channel having a plurality of spaced-apart projections on said channel, another channel member mounted on the edge of another abutting wall panel and having a plurality of slots receiving the projections on said other connecting member, said projections each including an aligned aperture through which a drop pin is removably disposed. 